MECH311

Assignment #3
Q1) A customer needs to clean up to a depth of 3mm on the 600mmx100mm surface of
100mm wide and 600mm long, 100mm thick slab of ASTM No.20 cast iron and
approached you for a price quote for machining as you are the production in-charge of a
machine shop. As it is the maintenance time for most of the machines, you have only one
slab milling machine and one end milling machine in working conditions. Hence, you
have decided to provide the price quote based on working with these two milling
machines. The maximum cutting speed allowed for the material is 0.6m/s, feed per tooth
is 0.25mm/tooth and the specific power is 1.3Ws/mm3. The cutting allowance for both
types of milling is 0.5*D at the start and end of cutting. That means, the total allowance
for each pass is D, where Dis the diameter of the cutter.
a) What would be rpm, actual cutting time, actual MRR, maximum power
required at the arbor and the maximum motor power if the mechanical
efficiency is 0.75 for the slab milling option. The cutter diameter is
120mm. Number of teeth is 7. The cutter width is sufficient enough to
cover the width of 100mm. (Hint: Maximum power has to be determined
based on maximum MRR) (9 Marks)
b) What would be the minimum number of passes (machining cuts) required,
rpm of the cutter, actual cutting time, actual MRR, maximum power
required at the spindle and the maximum motor power if the mechanical
efficiency is 0.75, for the end milling option. The cutter diameter is 50mm.
Number of teeth is 7. ( 9 Marks)
c) What would be machining cost based on actual cutting time if the rate is
2.5$/min for both machining operations. ( 2Marks)
d) If the maximum available power of the motor for both the machines are
1.6kW, which machine you would finally choose for machining and what
would be your final machining cost to quote to the customer? (2 Marks)
Q2) The planer has a 10HP motor and 75% of the motor power is available for
machining. The specific HP of the material is 0.67hp/in3/min. The material surface is
12x12. The feed rate is 0.25/stroke. The wheel rotational speed is 180rpm. Estimate
the depth of cut. This planer functions as a shaper. ( 6 Marks)
Q3) When carbon steel is machined with a HSS tool, the maximum allowed cutting speed
V is 100 fpm and the maximum feed is 0.02 inches per revolution (ipr). As a production
engineer, you have decided to reduce the length of a rod by 0.2inches in two machining
steps. The diameter of the rod is 2inches. Find the maximum MRR (approximate MRR)
after neglecting the cutting allowance. (Hint: depth of cut is half of the total cut length)
Estimate the following:
1. Depth of cut in inches (1 marks)
2. MRR with no cutting allowance in inches3/min (6 marks)